WRM Operation Roller , Block Area

Position Name :
Position Code :
Department :
Roller (WRM)
HR -
Wire Rod Mill
Sub-Department : Mill
Grade :
Engr./Jr. Engineer
Head Rolling Mill .
Reporting to :
Role Objective:
To act as a technical specialist in rolling operations ,ensuring precise control of
rolling parameters, loop formation, and inter-stand tension to achieve stable
deformation of billets into wire rod with consistent quality, optimized
productivity, and minimal process disturbances.
Role Responsibilities:
Rolling Operation: Control and stabilize rolling process across stands
ensuring uniform deformation and smooth material flow.
Process Parameter Control: Maintain and optimize speed, temperature,
reduction ratio, and inter-stand synchronization.
Loop Control: Monitor and maintain proper loop formation between stands
to regulate inter-stand tension and avoid cobbles.
Tension Control: Ensure controlled/low-tension rolling by balancing stand speeds

and loop height to prevent defects.
Block Mill Awareness: Maintain upstream conditions as per downstream block
mill requirements (temperature window, speed, size control).
IBA (Process Data Acquisition & Analysis): Analyze real-time data (motor load,
speed, temperature) to identify deviations and optimize process stability.
Heat Sequence: Ensure proper billet sequencing to maintain thermal consistency.
Controlled Cooling: Regulate cooling to achieve required metallurgical properties
and prevent defects.
Quality Assurance: Maintain dimensional accuracy, ovality control, and surface
quality.
Troubleshooting: Resolve loop instability, tension variation, cobbles, and stand
overloading issues.
Lubrication: Ensure proper lubrication of stands, guides, and bearings.
Coordination: Align with reheating furnace and downstream block mill operations.
Safety: Follow PPE, LOTO, and 5S practices.
Reporting: Maintain shift logs, parameter trends, and deviation reports.
Key Skills:
WRM rolling process and stand operation knowledge
Loop control and inter-stand tension management
Understanding of reduction ratios and deformation principles
Ability to interpret IBA data (load, speed, temperature)
Knowledge of block mill and finishing requirements
Troubleshooting of rolling defects and instability
Cooling practices and metallurgical awareness
Safety and 5S compliance

Key Performance Indicators (KPIs):
Process stability (loop & tension control)
Cobble reduction
Dimensional accuracy and surface quality
Mill uptime and downtime reduction
Yield improvement
Qualifications & Experience
Must Have:
Diploma / B.E. in Mechanical / Metallurgical Engineering
25 years in WRM / rolling mill operations
Strong knowledge of rolling fundamentals
Good to Have:
Exposure to block mill operations
Knowledge of loop control systems
Understanding of rolling defects and metallurgy